• Korean Journal of Materials Research
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• v.9 no.1
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• pp.73-80
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• 1999

The effect of alloy compositions of the bond coating on the plasma sprayed-thermal barrier coatings was investigated. The performance of the coating composed of Rene80/NiCrAl/ZrO$_2$-CeO$_2$-Y$_2$O$_3$ and Rene80/CoNiCrAlY/ZrO$_2$-CeO$_2$-Y$_2$O$_3$was evaluated by isothermal and thermal cyclic test in an ambient atmosphere at 115$0^{\circ}C$. The failure of Rene80/NiCrAl/ZrO$_2$-CeO$_2$-Y$_2$O$_3$ coatings was occurred at the bond coating/ceramic coating interface while Rene80/CoNiCrAlY/ZrO$_2$-CeO$_2$-Y$_2$O$_3$ coating was failed at the substrate/bond coating interface after thermal cyclic test. The lifetime of Rene80/NiCrAl/ZrO$_2$-CeO$_2$-Y$_2$O$_3$coatings was longer than Rene80/CoNiCrAlY/ZrO$_2$-CeO$_2$-Y$_2$O$_3$coating. The oxidation rate of the NiCrAl bond coating examined by TGA was lower than CoNiCrAlY bond coatings. In summary, these results suggest that Rene80/CoNiCrAlY/ZrO$_2$-CeO$_2$-Y$_2$O$_3$system as thermal barrier coating be not suitable considering the durability of the coating layer for high temperature oxidation and thermal stress.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.32 no.7
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• pp.569-575
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• 2008

In this study, disk type of thermal barrier coating system for gas turbine blade was isothermally aged in the furnace changing exposure time and temperature. For each aging condition, bond tests for three samples were conducted for evaluating degradation of adhesive or cohesive strength of thermal barrier coating system. For as-sprayed condition, the location of fracture in the bond test was in the middle of epoxy which have bond strength of 57 MPa. As specimens are degraded by thermal aging, bond strength gradually decreased and the location of failure was also changed from within top coat at the earlier stage of thermal aging to the interface between top coat and TGO at the later stage due to the delamination in the coating.

• Journal of Korea Foundry Society
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• v.17 no.4
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• pp.393-401
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• 1997

Commercial flake graphite cast iron substrate was coated with titanium powder by low pressure plasma spraying and was irradiated with a $CO_2$ laser to produce the wear resistant composite layer. From the experimental results of this study, it was possible to composite TiC particles on the surface layer by direct reaction between carbon existed in the cast iron matrix and titanium with thermal sprayed coating by remelting and alloying them using laser irradiation. The cooling rate of laser remelted cast iron substrate without titanium coating was about $1{\times}10^4$ K/s to $1{\times}10^5$ K/s in the order under the condition used in this study. The microstructure of alloyed layer consisted of three zones, that is, TiC particule crystallized zone (MHV $400{\sim}500$), the mixed zone of TiC particule+ledebulite (MHV $650{\sim}900$) and the ledebulite zone (MHV $500{\sim}700$). TiC particules were crystallized as a typical dendritic morphology. The secondary TiC dendrite arms were grown to the polygonized shape and were necking. And then the separated arms became cubic crystal of TiC at the slowly solidified zone. But in the rapidly solidified zone of fusion boundry, the fine granular TiC particules were grouped like grape.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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• 2004.11a
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• pp.66-74
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• 2004

The sliding wear behavior of $ZrO_2-22wt\%MgO\;(MZ)\;and\;ZrO_2-8wt\%Y_2O_3\;(YZ)$ deposited on a casting aluminum alloy with bond layer (NiCrCoAlY) by plasma spray against an SiC ball was investigated under dry test conditions at room temperature. At all load conditions, the wear mechanisms of the MZ and the YZ coatings were almost the same. The wear mechanisms involved the forming of a smooth film by material transferred on the sliding surface and pullout. The wear rate of the MZ coating was less than that of the YZ coating. With an increase normal load the wear rate of the studied coatings increased. The SEM was used to examine the sliding surfaces and elucidate likely wear mechanisms. The EDX analysis of the worn surface indicated that material transfer was occurred from the SiC ball to the disk. It was suggested that the material transfer played an important role in the wear performance.

• Journal of the Korean Ceramic Society
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• v.40 no.2
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• pp.123-127
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• 2003

The effects of process parameters on coating formation and coating properties were investigated using a fused and crushed Ti $O_2$powder by the Taguchi method and L$_{9}$(3$^4$) orthogonal array. The Taguchi analysis was conducted through the results of the coating properties affected strongly by plasma spraying parameters and Ti $O_2$powder was sprayed on Ti-6Al-4V alloy substrate. The coating properties were characterized by thickness, microhardness, porosity and surface roughness using optical microscopy, image analyzer and surface roughness tester respectively. An observed optimum condition of plasma spraying process could be found for potential use as a bioceramic coating.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.10
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• pp.3234-3242
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• 1996

This paper describes experimental results of modified small punch( MSP) test conducted to evaluate the fracure characteristics and mechanical properties of plasma sparayed zirconia ($ZrO_2$ stabilized with 8wt. % $Y_20_3$ : YSZ) NiCrAlY composite. The mixing ratios of YSZ/NiCrAlY were 0/100, 25/75, 50/50, 100/0 v.%. Test temperatures ranged from 293K to 1473K. This study is directed at development of thermal barrrier coating(TBC) system with superior heat resistance and mechanical properties. The microstructure and fracture process of the composite were examined by SEM and AE method. The mechanical properties of 100% YSZ were nearly independent of the temperatures tested in this study. In contrast, the NiCrAlY-containing composites showed a significant decrease of the mechanical properties above 1273K, showing a ductile- brittle transition behavior up to the temperature. Furthermore, it can seen that 25% YSZ/75% NiCrAlY composite gave the highest fracure strength and fracture energy among the mixing ratio tested over the temperature range.

• Corrosion Science and Technology
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• v.2 no.3
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• pp.155-160
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• 2003

Plasma spraying technique was used to fabricate functionally graded coating (FGC) of NiCrAIY/YSZ 8wt%$Y_2O_3-ZrO_2$ on a Co-base superalloy (HAYNES 188) substrate. Six layers were coated on the substrate for building up compositionally graded architecture. Conventional thermal barrier coating (TBC) of NiCrAIY/SZ with sharp interface was also fabricated. As-coated FGC and TBC samples were exposed at the temperature of $1100^{\circ}C$ for 10, 50, 100 hours in air. Microstructural change of thermally exposed samples was examined. Pores and microcracks were formed in YSZ layer due to evolution of thermal internal stress at high temperature. The amount of pores and microcracks in YSZ layer were increased with increasing exposure time at high temperature. High temperature oxidation of coatings occurred mainly at the NiCrAIY/YSZ interface. In comparison with the case of TBC. the increased area of the NiCrAIY/YSZ interface in FGC is likely to attribute to forming the higher amount of oxides.

• Journal of the Korean institute of surface engineering
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• v.30 no.5
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• pp.333-346
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• 1997

Plasma spray processes for functional coatings of tubular SOFC ( Soild oxide Fuel Cell).consisting of air electrode, oxide electrolyte, an fuel electrode, are optimized by fully saturated fractional factorial testing. Material and electric characteristics of each coating are analtsed by the implementation of SEM and optical microscope for evaluating microstructure and porosity, X-ray diffraction method for investigating compositional change between raw powder and sprayed coating, and Van der Pauw method for measuring electrical conductivity. LSM ($La_{0.65}Sr_{0.35}MnO_3$air electrode and Ni-YSL fuel electrode coatings have porosities of around 23~30% sufficient for effective fuel and oxidant gas supply to electrochemical reaction interfaces and electrical conductivities of around 90 S/cm and 1000 S/cm, respectively, enough for acting as current collecting electrodes. YSZ($ZrO_2-8mol%Y_2O_3$) electrolyte film has a high ionic conductivities of 0.05~0.07 S/cm at $1000^{\circ}C$ in air atmosphere, but appears to be somewhat too porous to reduce the thickness. for enhancing the cell efficiency. A unit tubular SOFC has beem fabricated by the optimized plasma spray processes for each functional coating and the cell. Its electrochemical chracteristics are investigated by measuring voltage-current and power density with variation of operationg temperature, radio of fuel to air gas flowrates, and total gas flowrate of reactants.

• Journal of the Korean institute of surface engineering
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• v.29 no.2
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• pp.81-92
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• 1996

The cementless fixation of bone ingrowth by porous coatings on artificial hip joint prostheses are replacing polymethylmethacrylate(PMMA) bone cement fixations. However, the major interests in the field of porous metal coating are environmental corrosivity accelerated by metal ion release, deterioration in the mechanical property of the coating, and the mechanical failure of the coatings as well as the substrate. Therefore, the selection of right materials for coatings and the development of porous coating techniques must be accomplished. Because of the existing problems in Ti and Ti alloys which are used extensively, this study is focused on the plasma spraying technique for coating on super stainless steel substrate. In order to determine the optimum conditions which satisfy the requirement for the porous coatings, under the plasma spraying, we selected the experimental parameters which extensively influenced on the characteristics of the coating through the pre-examination. Spray distance has been selected among 120, 160, and 200mm and primary gas flow rate among 70, 100, and 130 SCFH. Current and secondary gas($H_2$) flow rate was fixed at 400A, and 15 SCFH respectively. To understand the characteristics of the coatings, surface morphology, cross-sectional micro-structure, surface roughness, residual stress, and corrosion resistance were elucidated and the best conditions for the bone ingrowth improvement on artificial hip joint prostheses were found.

• Tribology and Lubricants
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• v.39 no.1
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• pp.13-20
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• 2023

Large drill bits may face high hardness ore and high working pressure when working. To optimize the use effect of large drill bits and prolong the use time, it is necessary to add a layer of pressure-resistant, wear-resistant, and low-friction coating on the surface of the drill bit. In this study, CoCrNiAlTi high-entropy alloy coatings and CoCrNiAlTi (70 wt%)-TiC (30 wt%) composite coatings are successfully prepared on Q235 steel by plasma spraying. The CoCrNiAlTi (70 wt%)-TiC (30 wt%) coating consists of FCC solid solution and a small amount of TiC phase. The effect of TiC on the composition phase, microhardness, and elastic modulus of HEA coating is studied by X-ray diffractometer (XRD) and microhardness tester. The effect of TiC on the friction and wear properties of HEA coatings is investigated using a wear tester. By improving the process parameters, the metallurgical bonding between the coating and the substrate is well combined, and a coating without pores and cracks is obtained. The experimental results confirm that the microhardness, elastic modulus, and wear resistance of CoCrNiAlTi-TiC composite coating are better, and the friction coefficient is lower.